Heat exchanger for an internal combustion engine

ABSTRACT

The present invention relates to a heat exchanger for an internal combustion engine, developed for cooling air by means of a cooling fluid, comprising
         a housing that comprises in its interior volume tubes for conducting the air to be cooled that extend through the housing,   an inlet and an outlet for the cooling fluid that are developed in the housing,   wherein the housing comprises several plate elements forming the housing,       

     wherein the inlet and the outlet are developed in different plate elements, and wherein the inlet and/or the outlet is or are provided in a protrusion of the plate elements, wherein the protrusion(s) has or have an extent along the housing that has a component perpendicular to a straight line connecting the inlet and the outlet.

This application claims priority from German Patent Application No. 102017219433.2 filed Oct. 30, 2017, which is hereby incorporated by reference in their entirety.

The present invention relates to a heat exchanger for an internal combustion engine

PRIOR ART

In the field of automobile technology, it is known to use charge-air coolers for cooling a gas supplied to the combustion engine in order to cool the air supplied to this engine. A heat exchanger is employed for this cooling in which the air can be cooled by means of a cooling fluid. Corresponding heat exchangers are disclosed for example in DE 10 2009 053884 A1, US 2012/0292002 A1, US 2008/0289833 A1, US 2009/0056922 A1, US 2010/0089548 A1, US 2006/0048759 A1, WO 2016/008854 A1, FR 2 968 753 B1, US 2013/0192803 A1, US 2013/0146267 A1, JP 5856068 B2 and JP 5856067 B2.

In said DE 10 2009 053884 A1 such heat exchanger comprises connections for supplying a cooling fluid. These connections open out into a housing on whose outside protrusions are provided. The housing is substantially comprised of two sheet metal parts that are joined together, wherein the two connections and the associated protrusions are formed in the same sheet metal part.

TECHNICAL PROBLEM ADDRESSED BY THE INVENTION

It was apparent to the inventors of the present application that with such heat exchanger designs adapting the heat exchanger to different conditions is only possible with difficulties. It was simultaneously found that in prior art, such as described for example in US 2009/0056922 A1, efficiency and durability are reduced due to the necessity of having to provide a separate component for the distribution of the cooling fluid, while, at the same time, a decrease in the consumption of material would be desirable.

DESCRIPTION OF THE INVENTION

The present invention aims to at least partially ameliorate the above described disadvantages.

The invention is defined by the heat exchanger as in described herein. Preferred embodiments are defined herein.

According to the invention a heat exchanger for an internal combustion engine, developed for cooling air by means of a cooling fluid, comprises a housing. This housing comprises in its interior volume tubes for conducting the air to be cooled, which tubes extend through the housing. Said cooling fluid can typically be a cooling liquid, such as for example water. However, other fluids can also be utilized. The tubes serving for conducting the air to be cooled are physically separated from the region through which the cooling fluid can pass such that the cooling fluid and the air to be cooled do not mix. The housing comprises according to the invention an inlet and an outlet for the cooling fluid through which this fluid can enter and exit again.

The housing comprises several plate elements that form the housing, wherein the inlet and the outlet for the cooling fluid are developed in different plate elements. These plate elements are those components of the heat exchanger that form the housing. These plate elements are typically comprised of metal plates that can be joined by hard- or soft-soldering.

According to the invention the inlet and/or the outlet are provided in a protrusion of the plate elements. These protrusions are directed outwardly. The protrusion has an extent along the housing, which includes a component that extends perpendicularly to a straight line connecting the inlet and the outlet. The extent of the protrusion is a straight line extending along the protrusion and is the longest dimension of the protrusion. Stated differently, the extent of the protrusion is along the longest direction of the protrusion. If the protrusion is not comprised of a single linear element but rather of several substantially linear elements, it may have different extension directions in each of the individual elements. In such case it is sufficient for one of the elements to extend along said direction.

The protrusion in which the inlet and/or outlet is or are provided, serves for enabling the cooling fluid to be distributed. This avoids having to provide a separate device for the distribution of the cooling fluid. As stated above, this leads to the fact that the structure of the heat exchanger is less complex and thus avoids the stated disadvantages in this respect. In particular, material expenses can be saved since fewer components are installed and therefore less material is needed. It was furthermore found that corresponding heat exchangers are of advantage in the case of long and narrow spaces into which they are to be installed and that they are also comparatively light of weight with respect to their heat exchange capacity. Due to the good and uniform distribution of the cooling fluid because of the disposition of the protrusions, the cooling efficiency is increased. In addition, the uniform distribution of the cooling fluid avoids having the fluid stagnate or having it only move very slowly at certain sites. Such stagnation would entail the risk that at those sites the cooling fluid (should it be a liquid) starts to boil which, in turn, could lead to damages and to efficiency loss.

In contrast to the present invention, in prior art the cooling fluid is distributed across a separate cooling fluid distributor, whereas this can be omitted in the present case.

It is herein preferred that this extension direction is substantially perpendicular to a direction in which the tubes for conducting the air to be cooled extend. This results in the efficient distribution of the cooling fluid with respect to the tubes, whereby these can be cooled better.

Thereby that the inlet and the outlet are developed in different plate elements the heat exchanger can easily be adapted to different requirements thereby that, for example, only one of the plate elements needs to be exchanged.

It is preferred for the tubes to open out into base plates of the heat exchanger and for the inlet and/or the outlet for the cooling fluid to be developed in a plate element that is integral with the associated base plate. By base plate is herein understood a plate through which the air can enter into the tubes for conducting this air to be cooled, i.e. that has openings that align with corresponding openings in the base plates and are connected therewith. Thereby that the inlet and/or the outlet is/are developed in a plate element that includes an associated base plate, a corresponding heat exchanger is easy of production and low of complexity. The results are lowered production costs.

It is preferred for the base plate and the component of the plate element into which the inlet and/or the outlet open out, are substantially perpendicular to one another. A corresponding heat exchanger can be produced cost-effectively.

It is furthermore preferred for the plate element of the base plate to comprise additionally encompassing components that border on the base plate, wherein these encompassing components, together with the component into which the outlet or the inlet open out, encompass the base plate. Through these additional encompassing components, the plate element of the base plate has overall an apron form. Accordingly, it can facilitate the construction of the heat exchanger which, in turn, manifests itself in decreased costs.

It is preferred for the plate element in which the inlet and/or the output is/are provided to overlap another plate element of the housing such that the other plate element partially delimits the hollow volume formed by the protrusion. Through this overlap the outflow of the cooling fluid from the hollow volume can be controlled since the size of the overlap can be selected as desired at the time of production of the heat exchanger. This leads to improved adaptability of the heat exchanger to changing conditions.

It is preferred for the housing to have substantially the form of a parallelepiped and for the inlet and the outlet to be developed on the same side of the parallelepiped. Such heat exchanger saves space and can readily be assembled and mounted since the inlet and the outlet are developed on the same side.

It is furthermore preferred that at least one, preferably both, protrusions are developed in the shape of an L. Through the corresponding development of the protrusions the cooling fluid can be well distributed. However, other forms can also achieve corresponding advantages.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a perspective view of a heat exchanger according to a first embodiment.

FIG. 2A shows an exploded representation of the heat exchanger of FIG. 1.

FIG. 2B shows the heat exchanger of FIG. 2A from different views

FIG. 3 shows, in comparison, an inflow of prior art.

FIG. 4 shows a functional principle of an inflow according to the first embodiment.

FIGS. 5A to 5C show a second embodiment of the invention.

FIG. 6A to 6C show a third embodiment of the invention.

FIG. 7 shows a fourth embodiment of the invention.

FIG. 8 shows a fifth embodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 shows a perspective view of a heat exchanger 10 according to a first embodiment.

FIG. 2A shows an exploded representation of the heat exchanger of FIG. 1, while FIG. 2B shows the heat exchanger from different views.

A heat exchanger 10 comprises a housing 11 through which extend the tubes 25 for conducting through them the air to be cooled. These tubes open out into base plates 24 that form an interface to the surrounding of the heat exchanger. The base plates 24, provided at the inlet and outlet side of the tubes, together with side plates 16, lower plate 30 and upper plate 18 form the housing 11 which has the form of a parallelepiped. In the context of the present invention side plates 16, lower plate 30, upper plate 18 and base plates 24 are denoted as “plate elements”. In tubes 25 are received fins 25′ that are produced of a metal material and increase the heat conduction. These fins 25′ extend between the walls of the tubes 25.

The side plates 16 have a simple rectangular shape, while the lower plate 30 has the form of a rectangle with projecting side edges that overlap the side plates 16.

At these overlaps the lower plate 30 and the side plates 16 are connected. The upper plate 18 has essentially the shape of an H, wherein it is connected at its longitudinal sides with the side plates 16. At the openings of the H, elements 20 of the base plate 24 are emplaced and connected with the upper plate 18. Each of these elements 20 includes a protrusion 21 that extends perpendicularly to the extension direction of tubes 25 for conducting the air to be cooled.

In these protrusions 21 are provided an inlet 12 and an outlet 14 for the cooling fluid (for example water). The cooling fluid entering through inlet 12 spreads out in the protrusion 21 perpendicular to the direction of flow of the air passing through that is to be cooled, while it flows simultaneously between the pipes in the direction of the lower plate 30. The cooling fluid subsequently exits the heat exchanger 10 again through outlet 14 provided in protrusion 21. To connect to the cooling air supply, further, adapters 26 and 28 are provided at the inlet or outlet, respectively, for the air to be cooled.

As is evident in FIG. 4, there is an overlap a between the upper plate 18 and the hollow volume 21 that is delimited by the protrusion 12. Through this overlap the area through which the cooling fluid can exit can be controlled. The cooling fluid must subsequently flow off as indicated in FIG. 4 by the dashed line. Since the overlap a can be varied in simple manner, a corresponding heat exchanger can be readily adapted to different applications. This differs from the example of prior art shown in FIG. 3 in which such variable adaptation is not possible. Herein the cooling fluid enters the hollow volume 20′ through inlet 12′, without the capability being available of intentionally regulating the outflow of the cooling fluid.

A second embodiment of the invention will be described below with reference to FIGS. 5A to 5C. The essential difference from the first embodiment resides therein that the base plate 124 comprises further components 120′ which, together with the component 120, encompass the base plate 124 in the form of an apron. Into this apron the remaining components of the housing 111 can be introduced, with this apron stabilizing these components. In this respect such a parallelepiped-shaped housing 110 can be produced more easily. At the sides surrounding the base plate 124 which adjoin the protrusion 121 the component 120′ is not as high as on other sides. Since according to experience the forces acting at these sites are comparatively low, material can consequently be saved without impairing the stability and robustness of the heat exchanger 110. Apart from said differences, the implementation of the housing is otherwise identical. In FIG. 5A and 5B the reference numbers 126 and 128 denote the corresponding adapters.

A third embodiment of the invention will be described with reference to FIGS. 6A to 6C. This embodiment involves a modification of the second embodiment depicted in FIGS. 5A and 5B. While in the second embodiment the additional components 120′ extend at a variable height with respect to the base plate 124, the components 222′ in the third embodiment have a constant height with respect to the base plate 224. Such implementation of the plate element 220 leads to increased robustness of the heat exchanger 210 since no height variations occur. In this embodiment the inlet and the outlet are also provided on opposite faces of the parallelepiped, which decreases the flow resistance and can consequently lead to an increased possible through-flow rate. In this regard, the cooling efficiency can be improved.

A fourth embodiment of the invention will be described below with reference to FIG. 7. Herein only one of the protrusions 321′ is provided in the form of an L. Such implementation of the protrusion leads to improved distribution of the cooling fluid and consequently to lower flow resistance. This is of advantage especially when this protrusion is provided at the inlet for the cooling fluid.

In FIG. 8 a fifth embodiment of the invention is shown. Herein the protrusions of the inlet and of the outlet are each shaped like an L. Such implementation reduces the flow resistance still further. 

1.-7. (canceled)
 8. A heat exchanger for an internal combustion engine, developed for cooling air by means of a cooling fluid, comprising: a housing that comprises in its interior volume tubes for conducting the air to be cooled that extend through the housing; an inlet and an outlet for the cooling fluid that are developed in the housing, wherein the housing comprises several plate elements that form the housing, wherein the inlet and the outlet are developed in different plate elements, and wherein the inlet and/or the outlet is or are provided in a protrusion of the plate elements, wherein the protrusion has or have an extent along the housing, that has a component perpendicular to a straight line connecting the inlet and the outlet.
 9. A heat exchanger according to claim 8, wherein the tubes open out into base plates of the heat exchanger and wherein the inlet and/or the outlet for the cooling fluid is and/or are developed in a plate element that is integral with the associated base plate.
 10. A heat exchanger according to claim 9, wherein the base plate and the component of the plate element into which the inlet or the outlet open out are substantially perpendicular with respect to one another.
 11. A heat exchanger according to claim 10, wherein the plate element of the base plate further comprises encompassing components that border on the base plate and wherein these encompassing components, together with the component into which the inlet or the outlet opens out, encompass the base plate.
 12. A heat exchanger according to claim 8, wherein the plate element in which the inlet and/or the outlet is or are provided overlaps another plate element of the housing such that the other plate element partially delimits the hollow volume formed by the protrusion.
 13. A heat exchanger according to claim 8, wherein the housing has substantially the form of a parallelepiped and wherein the inlet and the outlet are developed on the same side of the parallelepiped.
 14. A heat exchanger according to claim 8, wherein at least one protrusion is in the shape of an L.
 15. A heat exchanger according to claim 9, wherein the plate element in which the inlet and/or the outlet is or are provided overlaps another plate element of the housing such that the other plate element partially delimits the hollow volume formed by the protrusion.
 16. A heat exchanger according to claim 10, wherein the plate element in which the inlet and/or the outlet is or are provided overlaps another plate element of the housing such that the other plate element partially delimits the hollow volume formed by the protrusion.
 17. A heat exchanger according to claim 11, wherein the plate element in which the inlet and/or the outlet is or are provided overlaps another plate element of the housing such that the other plate element partially delimits the hollow volume formed by the protrusion.
 18. A heat exchanger according to claim 9, wherein the housing has substantially the form of a parallelepiped and wherein the inlet and the outlet are developed on the same side of the parallelepiped.
 19. A heat exchanger according to claim 10, wherein the housing has substantially the form of a parallelepiped and wherein the inlet and the outlet are developed on the same side of the parallelepiped.
 20. A heat exchanger according to claim 11, wherein the housing has substantially the form of a parallelepiped and wherein the inlet and the outlet are developed on the same side of the parallelepiped.
 21. A heat exchanger according to claim 12, wherein the housing has substantially the form of a parallelepiped and wherein the inlet and the outlet are developed on the same side of the parallelepiped.
 22. A heat exchanger according to claim 9, wherein the housing has substantially the form of a parallelepiped and wherein the inlet and the outlet are developed on the same side of the parallelepiped.
 23. A heat exchanger according to claim 9, wherein at least one protrusion is in the shape of an L.
 24. A heat exchanger according to claim 10, wherein at least one protrusion is in the shape of an L.
 25. A heat exchanger according to claim 11, wherein at least one protrusion is in the shape of an L.
 26. A heat exchanger according to claim 20, wherein at least one protrusion is in the shape of an L.
 27. A heat exchanger according to claim 21, wherein at least one protrusion is in the shape of an L. 